Outsole plate

ABSTRACT

A sole structure for an article includes a first layer including a first bundle of fibers affixed to a first substrate, a second layer including a second bundle of fibers affixed to a second substrate, a traction element having a first portion disposed between the first substrate and the second substrate and a second portion extending from one of the first layer and the second layer. The sole structure further includes a resin that consolidates the first bundle of fibers and the second bundle of fibers, and secures the traction element between the first bundle of fibers and the second bundle of fibers.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Application No. 62/658,285, filed Apr. 16, 2018, thecontents of which are hereby incorporated by reference in theirentirety.

TECHNICAL FIELD

The present disclosure relates to articles of footwear including solestructures incorporating outsole plates.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

Articles of footwear conventionally include an upper and a solestructure. The upper may be formed from any suitable material(s) toreceive, secure, and support a foot on the sole structure. The upper maycooperate with laces, straps, or other fasteners to adjust the fit ofthe upper around the foot. A bottom portion of the upper, proximate to abottom surface of the foot, attaches to the sole structure.

Sole structures generally include a layered arrangement extendingbetween a ground surface and the upper. One layer of the sole structureincludes an outsole that provides abrasion-resistance and traction withthe ground surface. The outsole may include an outsole plate formed of arigid or semi-rigid material that provides rigidity and energydistribution across the sole structure. The outsole may be provided withone or more types of traction elements for maximizing engagement with aground surface. In some cases, the traction elements may be fixed to theoutsole plate. Alternatively, the traction elements may beinterchangeable and/or may be formed from rubber or other materials thatimpart durability and wear-resistance, as well as enhancing tractionwith the ground surface.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected configurations and are not intended to limit the scope of thepresent disclosure.

FIG. 1 is a side elevation view of an article of footwear in accordancewith principles of the present disclosure;

FIG. 2 is a cross-sectional view of the article of footwear of FIG. 1,taken along section line 2-2 of FIG. 1;

FIG. 3 is an exploded view of the article of footwear of FIG. 1 showingan upper, a midsole, and an outsole;

FIG. 4 is a bottom plan view of an outsole in accordance with principlesof the present disclosure;

FIG. 5A is a cross-sectional view of the outsole of FIG. 4, taken alongsection line 5-5 of FIG. 4 and showing the outsole in an unmolded firststate;

FIG. 5B is a cross-sectional view of the outsole of FIG. 4, taken alongsection line 5-5 of FIG. 4 and showing the outsole in a molded secondstate;

FIG. 6A is an enlarged fragmentary view of the outsole plate of FIG. 5A,taken at area 6A of FIG. 5A;

FIG. 6B is an enlarged fragmentary view of the outsole plate of FIG. 5B,taken at area 6B of FIG. 5B;

FIG. 7 is an enlarged fragmentary perspective view of a lower layer ofan outsole plate in accordance with the principles of the presentdisclosure;

FIG. 8 is an exploded view of a lower layer of an outsole plate inaccordance with the principles of the present disclosure;

FIGS. 9A-9E are views of various examples of arrangements of fiberstrands used in forming support plies of the outsole of FIG. 4;

FIG. 10 is an exploded view of an upper layer of an outsole plate inaccordance with the principles of the present disclosure;

FIG. 11A-G are plan views of various examples of arrangements of fiberstrands used in forming torsion plies of the outsole of FIG. 4;

FIG. 12A-10F are perspective views of various examples of aground-engaging assembly of an outsole plate in accordance with theprinciples of the present disclosure;

FIG. 13A is a perspective view of a mold for use in forming an outsoleplate in accordance with the principles of the present disclosure, themold shown in conjunction with a stack of outsole plate components priorto being assembled into an outsole plate;

FIG. 13B is a cross-section view of the mold of FIG. 13A, the mold shownin conjunction with a stack of outsole plate components enclosed withina mold cavity prior to a resin curing step;

FIG. 13C is a cross-section view of the mold of FIG. 13A, the mold shownin conjunction with a stack of fibers enclosed within a mold cavityafter a resin curing step; and

FIG. 13D is a perspective view of the mold of FIG. 13A, the mold shownin conjunction with a formed outsole plate.

Corresponding reference numerals indicate corresponding parts throughoutthe drawings.

DETAILED DESCRIPTION

Example configurations will now be described more fully with referenceto the accompanying drawings. Example configurations are provided sothat this disclosure will be thorough, and will fully convey the scopeof the disclosure to those of ordinary skill in the art. Specificdetails are set forth such as examples of specific components, devices,and methods, to provide a thorough understanding of configurations ofthe present disclosure. It will be apparent to those of ordinary skillin the art that specific details need not be employed, that exampleconfigurations may be embodied in many different forms, and that thespecific details and the example configurations should not be construedto limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particularexemplary configurations only and is not intended to be limiting. Asused herein, the singular articles “a,” “an,” and “the” may be intendedto include the plural forms as well, unless the context clearlyindicates otherwise. The terms “comprises,” “comprising,” “including,”and “having,” are inclusive and therefore specify the presence offeatures, steps, operations, elements, and/or components, but do notpreclude the presence or addition of one or more other features, steps,operations, elements, components, and/or groups thereof. The methodsteps, processes, and operations described herein are not to beconstrued as necessarily requiring their performance in the particularorder discussed or illustrated, unless specifically identified as anorder of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” “attached to,” or “coupled to” another element or layer,it may be directly on, engaged, connected, attached, or coupled to theother element or layer, or intervening elements or layers may bepresent. In contrast, when an element is referred to as being “directlyon,” “directly engaged to,” “directly connected to,” “directly attachedto,” or “directly coupled to” another element or layer, there may be nointervening elements or layers present. Other words used to describe therelationship between elements should be interpreted in a like fashion(e.g., “between” versus “directly between,” “adjacent” versus “directlyadjacent,” etc.). As used herein, the term “and/or” includes any and allcombinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describevarious elements, components, regions, layers and/or sections. Theseelements, components, regions, layers and/or sections should not belimited by these terms. These terms may be only used to distinguish oneelement, component, region, layer or section from another region, layeror section. Terms such as “first,” “second,” and other numerical termsdo not imply a sequence or order unless clearly indicated by thecontext. Thus, a first element, component, region, layer or sectiondiscussed below could be termed a second element, component, region,layer or section without departing from the teachings of the exampleconfigurations.

One aspect of the disclosure provides a sole structure for an article offootwear. The sole structure includes a first layer including a firstbundle of fibers affixed to a first substrate, a second layer includinga second bundle of fibers affixed to a second substrate, a tractionelement having a first portion disposed between the first substrate andthe second substrate and a second portion extending from one of thefirst layer and the second layer, and a resin that consolidates thefirst bundle of fibers and the second bundle of fibers.

Implementations of the disclosure may include one or more of thefollowing optional features. In some examples, the first portion of thetraction element is a flange and the second portion of the tractionelement is a ground-engaging projection extending from the flange. Theprojection may include a constantly decreasing taper in a directionextending away from the flange. The flange may be in contact with atleast one of the fibers of the first bundle of fibers and with thefibers of the second bundle of fibers.

In some examples, at least one of the first portion of the tractionelement and the second portion of the traction element is in contactwith at least one of the fibers of the first bundle of fibers and withat least one of the fibers of the second bundle of fibers.

In some examples, the second portion of the traction element extendsthrough at least one of the first substrate and the second substrate. Insome implementations, at least one of the first substrate and the secondsubstrate includes an aperture for receiving the second portion of thetraction element. The second portion of the traction element may extendthrough the fibers of at least one of the first bundle of fibers and thesecond bundle of fibers. In some implementations, the second portion ofthe traction element may extend between adjacent segments of at leastone of the first bundle of fibers and the second bundle of fibers.

In some implementations, the first portion of the traction element is ananchor portion and the second portion of the traction element is acleat. Here, the anchor portion may be disposed between the firstsubstrate and the second substrate. Further, the anchor portion mayinclude a cleat-retention feature operable to receive and retain aportion of the cleat therein. Here, the cleat-retention feature mayinclude a first series of threads operable to matingly receive a secondseries of threads of the cleat.

In some examples, the resin is a polymeric resin. Further, the firstbundle of fibers and the second bundle of fibers may include at leastone of carbon fibers, boron fibers, glass fibers, and polymeric fibers.In some examples, the first bundle of fibers and the second bundle offibers are affixed to respective ones of the first substrate and thesecond substrate via stitching. At least one of the first bundle offibers and the second bundle of fibers includes first fibers comingledwith second fibers, the second fibers including at least one of adifferent length, thickness, melting temperature, and tensile strengththan the first fibers. At least one of the stitching, the firstsubstrate, the second substrate, the first fibers, and the second fibersmay comprise a thermoplastic material.

In some implementations, at least one of the fibers of the first bundleof fibers, the fibers of the second bundle of fibers, the firstsubstrate, and the second substrate comprise a thermoplastic material.

In some examples, the sole structure including any of the aforementionedfeatures may be incorporated into an article of footwear. Here, thetraction element may form a portion of a ground-engaging surface of thearticle of footwear.

Another aspect of the disclosure provides a method of forming a solestructure for an article of footwear. The method includes attaching afirst bundle of fibers to a first substrate to form a first componentand attaching a second bundle of fibers to a second substrate to form asecond component. The method also includes positioning a first portionof a traction element between the first substrate and the secondsubstrate and extending a second portion of the traction element fromone of the first component and the second component. The method furtherincludes consolidating the first bundle of fibers and the second bundleof fibers with a resin.

Implementations of this aspect of the disclosure may include one or moreof the following optional features. In some implementations, positioninga first portion of a traction element between the first substrate andthe second substrate includes positioning a flange of the tractionelement between the first substrate and the second substrate andextending a second portion of the traction element from one of the firstcomponent and the second component includes extending a projection ofthe traction element from the one of the first component and the secondcomponent. Here the method may include providing the projection with aconstantly decreasing taper in a direction extending away from theflange. Additionally or alternatively, the method may also includeplacing the flange in contact with at least one of the fibers of thefirst bundle of fibers and with the fibers of the second bundle offibers.

In some examples, the method includes placing at least one of the firstportion and the second portion of the traction element in contact withat least one of the fibers of the first bundle of fibers and with thefibers of the second bundle of fibers. The method may also includeplacing the fibers of the first bundle of fibers in contact with thesecond substrate. Optionally, the method may include placing the firstsubstrate in contact with the second substrate.

In some configurations, the method includes extending the second portionof the traction element through at least one of the first substrate andthe second substrate. The method may also include extending the secondportion of the traction element through the fibers of at least one ofthe first bundle of fibers and the second bundle of fibers. The methodmay further include extending the second portion of the traction elementbetween adjacent segments of at least one of the first bundle of fibersand the second bundle of fibers.

In some implementations, positioning a first portion of a tractionelement between the first substrate and the second substrate includespositioning an anchor portion of the traction element between the firstsubstrate and the second substrate and extending a second portion of thetraction element from one of the first component and the secondcomponent includes extending a cleat from the one of the first componentand the second component. Here, the method may include positioning theanchor portion between the first substrate and the second substrate.Additionally or alternatively, the method may include providing theanchor portion with a cleat-retention feature operable to receive andretain a portion of the cleat therein. Here, the method may furtherinclude providing the cleat-retention feature with a first series ofthreads operable to matingly receive a second series of threads of thecleat.

In some examples, consolidating the first bundle of fibers and thesecond bundle of fibers with resin includes consolidating the firstbundle of fibers and the second bundle of fibers with a polymeric resin.When attaching a first bundle of fibers to a first substrate andattaching a second bundle of fibers to a second substrate, the methodmay include attaching a first bundle of fibers and a second bundle offibers including at least one of carbon fibers, boron fibers, glassfibers, and polymeric fibers. Additionally or alternatively, whenattaching a first bundle of fibers to a first substrate and attaching asecond bundle of fibers to a second substrate, the method may includeattaching a first bundle of fibers and a second bundle of fibers torespective ones of the first substrate and the second substrate viastitching. Here, attaching a first bundle of fibers to a first substrateand attaching a second bundle of fibers to a second substrate mayinclude attaching a first bundle of fibers and a second bundle of fiberseach having first fibers comingled with second fibers, the second fibersincluding at least one of a different length, thickness, meltingtemperature, and Young's modulus than the first fibers. Here, the methodmay further include forming at least one of the stitching, the firstsubstrate, the second substrate, the first fibers, and the second fibersfrom a thermoplastic material.

In some configurations, the method includes forming at least one of thefibers of the first bundle of fibers, the fibers of the second bundle offibers, the first substrate, and the second substrate from athermoplastic material. The sole structure including any of theaforementioned features may be incorporated into an article of footwear.Here, the method may include forming a portion of a ground-contactingsurface of the article of footwear with the traction element.

Another aspect of the disclosure provides a sole structure for anarticle of footwear. The sole structure formed by a process includingattaching a first bundle of fibers to a first substrate to form a firstcomponent and attaching a second bundle of fibers to a second substrateto form a second component. The process also includes positioning afirst portion of a traction element between the first substrate and thesecond substrate. The process further includes extending a secondportion of the traction element from one of the first component and thesecond component and consolidating the first bundle of fibers and thesecond bundle of fibers with a resin.

Implementations of this aspect of the disclosure may include one or moreof the following optional features. In some examples, the first portionis a flange and the second portion is a ground-engaging projectionextending from the flange. Here, the projection may include a constantlydecreasing taper in a direction extending away from the flange.Optionally, the flange may be in contact with at least one of the fibersof the first bundle of fibers and with the fibers of the second bundleof fibers.

In some configurations, at least one of the first portion and the secondportion of the traction element is in contact with at least one of thefibers of the first bundle of fibers and with the fibers of the secondbundle of fibers. The fibers of the first bundle of fibers may be incontact with the second substrate. The first substrate may also be incontact with the second substrate.

In some implementations, the second portion of the traction elementextends through at least one of the first substrate and the secondsubstrate. The second portion of the traction element may also extendthrough the fibers of at least one of the first bundle of fibers and thesecond bundle of fibers. Optionally, the second portion of the tractionelement may extend between adjacent segments of at least one of thefirst bundle of fibers and the second bundle of fibers.

In some examples, the first portion of the traction element is an anchorportion and the second portion of the traction element is a cleat. Here,the anchor portion may be disposed between the first substrate and thesecond substrate. Additionally or alternatively, the anchor portionincludes a cleat-retention feature operable to receive and retain aportion of the cleat therein. The cleat-retention feature may include afirst series of threads operable to matingly receive a second series ofthreads of the cleat.

In some configurations, the resin is a polymeric resin. The first bundleof fibers and the second bundle of fibers may include at least one ofcarbon fibers, boron fibers, glass fibers, and polymeric fibers. Thefirst bundle of fibers and the second bundle of fibers may be stitchedto respective ones of the first substrate and the second substrate viastitching. Here, at least one of the first bundle of fibers and thesecond bundle of fibers may include first fibers comingled with secondfibers, the second fibers including at least one of a different length,thickness, melting temperature, and Young's modulus than the firstfibers. Optionally, at least one of the stitching, the first substrate,the second substrate, the first fibers, and the second fibers mayinclude a thermoplastic material.

In some implementations, at least one of the fibers of the first bundleof fibers, the fibers of the second bundle of fibers, the firstsubstrate, and the second substrate include a thermoplastic material.The sole structure including any of the above-mentioned features may beincorporated into an article of footwear. Here, the traction element mayform a portion of a ground-contacting surface of the article offootwear.

Referring to FIGS. 1-3, an article of footwear 10 includes an upper 100and sole structure 200. The article of footwear 10 may be divided intoone or more regions. The regions may include a forefoot region 12, amid-foot region 14, and a heel region 16. The forefoot region 12 may besubdivided into a toe portion corresponding with phalanges, and a ballportion associated with metatarsal bones of a foot. The mid-foot region14 may correspond with an arch area of the foot, and the heel region 16may correspond with rear portions of the foot, including a calcaneusbone. The footwear 10 may further include an anterior end 18 associatedwith a forward-most point of the forefoot region 12, and a posterior end20 corresponding to a rearward-most point of the heel region 16. Alongitudinal axis A_(F) of the footwear 10 extends along a length of thefootwear 10 from the anterior end 18 to the posterior end 20, andgenerally divides the footwear 10 into a medial side 22 and a lateralside 24. Accordingly, the medial side 22 and the lateral side 24respectively correspond with opposite sides of the footwear 10 andextend through the regions 12, 14, 16.

The upper 100 includes interior surfaces that define an interior void102 configured to receive and secure a foot for support on solestructure 200. The upper 100 may be formed from one or more materialsthat are stitched or adhesively bonded together to form the interiorvoid 102. Suitable materials of the upper may include, but are notlimited to, mesh, textiles, foam, leather, and synthetic leather. Thematerials may be selected and located to impart properties ofdurability, air-permeability, wear-resistance, flexibility, and comfort.

In some examples, one or more fasteners 110 extend along the upper 100to adjust a fit of the interior void 102 around the foot and toaccommodate entry and removal of the foot therefrom. The upper 100 mayinclude apertures 112 such as eyelets and/or other engagement featuressuch as fabric or mesh loops that receive the fasteners 110. Thefasteners 110 may include laces, straps, cords, hook-and-loop, or anyother suitable type of fastener. The upper 100 may include a tongueportion 114 that extends between the interior void 102 and thefasteners.

With reference to FIGS. 2 and 3, in some examples the upper 100 includesa strobel 104 having a bottom surface opposing the sole structure 200and top surface formed on an opposite side from the bottom surface anddefining a footbed 106 of the interior void 102. Stitching or adhesivesmay secure the strobel to the upper 100. The footbed 106 may becontoured to conform to a profile of the bottom surface (e.g., plantar)of the foot. Optionally, the upper 100 may also incorporate additionallayers such as an insole 108 or sockliner that may be disposed upon thestrobel 104 and reside within the interior void 102 of the upper 100 toreceive a plantar surface of the foot to enhance the comfort of thearticle of footwear 10. An ankle opening 116 in the heel region 16 mayprovide access to the interior void 102. For example, the ankle opening116 may receive a foot to secure the foot within the interior void 102and to facilitate entry and removal of the foot from and to the interiorvoid 102.

With reference to FIGS. 2 and 3, the sole structure includes a midsole202 and an outsole 204. Generally, the midsole 202 is disposedintermediate the outsole 204 and the upper 100, and is configured toattenuate forces associated with impact of the sole structure 200 with aground surface. The midsole 202 may extend fully or partially along alength of the footwear 10. In some examples the midsole 202 may befragmentary, such that a plurality of midsole segments are distributedalong the sole structure 200. Stitching or adhesives may secure themidsole 202 to the upper 100.

The midsole 202 may be formed from any suitable materials that compressresiliently under applied loads. Examples of suitable polymer materialsfor the foam materials include ethylene vinyl acetate (EVA) copolymers,polyurethanes, polyethers, and olefin block copolymers. The foam canalso include a single polymeric material or a blend of two or morepolymeric materials including a polyether block amide (PEBA) copolymer,the EVA copolymer, a thermoplastic polyurethane (TPU), and/or the olefinblock copolymer.

The outsole 204 includes an upper surface 206 and a ground-engagingsurface 208 formed on an opposite side from the upper surface 206. Theoutsole 204 is a full-length outsole 204, and extends continuously froma first end 210 at the anterior end 18 of the footwear 10 to a secondend 212 at the posterior end 20, and from the medial side 22 to thelateral side 24.

With reference the FIGS. 2-6B, components of the outsole 204 include anoutsole plate 214, one or more first traction elements 216, and a webbedground-engaging assembly 218. As discussed in greater detail below, theoutsole 204 is formed by joining each of the components 214, 216, 218together using a curable resin 220. For example, the outsole plate 214,the first traction elements 216, and the ground-engaging assembly 218may be disposed within a mold cavity and subjected to a combination ofpressure and heat, whereby the resin 220 is delivered to the mold cavityand impregnates and/or encapsulates each the components 214, 216, 218 toform a unitary structure. Accordingly, the outsole plate 214, the firsttraction elements 216, and the webbed ground-engaging assembly 218 maycooperate to define the ground-engaging surface 208 of the outsole 204.

With reference to FIGS. 2 and 4, the outsole plate 214 extends from thefirst end 210 to the second end 212. In the illustrated example, theoutsole plate 214 is a full-length plate. Accordingly, the first end 210of the outsole plate 214 is coincident with the anterior end 18 of thefootwear 10, while the second end 212 is coincident with the posteriorend 20 of the footwear. Alternatively, the outsole plate 214 may be apartial-length plate that extends from the anterior end 18 to anintermediate portion of the footwear 10. Additionally or alternatively,the outsole plate 214 may be fragmentary, and include a plurality ofindividual segments disposed along the sole structure.

With reference to FIGS. 2-6B, the outsole plate 214 is formed of a oneor more layers 221, 222 stacked in series and bonded together by theresin 220. In one example, the outsole plate 214 includes a lower layer221 and an upper layer 222, as shown in FIGS. 2 and 3. As explained ingreater detail below, each of the layers 221, 222 includes at least oneply 223, 224 formed from one or more strands 226, 226 a-226 c of fibers227 arranged on substrates 228 in selected patterns to impart stiffnessand gradient load paths throughout the outsole plate 214. Each of thelower layer 221 and the upper layer 222 may be formed with variousquantities and arrangements of the plies 223, 224 to impart desiredtorsional properties to the outsole plate 214. Accordingly, the lowerlayer 221 and the upper layer 222 are generically represented in FIGS. 2and 3, while examples of configurations of the plies 223, 224 for eachof the layers 221, 222 are described below. With continued reference toFIGS. 2 and 3, the lower layer 222 of the outsole plate 214 is providedwith preformed apertures 225 for receiving the traction elements 216, asdiscussed below.

Each strand 226 may refer to a tow of a plurality of fibers 227, amonofilament, yarn, or polymer pre-impregnated tows. As used herein, theterm “tow” or “strand” refers to a bundle (i.e., plurality of filaments(e.g., fiber) that may be twisted or untwisted and each tow may bedesignated a size associated with a number of fibers 227 thecorresponding tow contains. For instance, a single strand 226 may rangein size from about 1,000 fibers per bundle to about 48,000 fibers perbundle.

In some configurations, the fibers 227 associated with each strand 226include at least one of carbon fibers, boron fibers, glass fibers, andpolymeric or thermoplastic fibers. Fibers 227 such as carbon fibers,aramid fibers, and boron fibers may provide a high Young's modulus whileglass fibers (e.g., fiberglass) and polymer fibers (e.g., syntheticfibers) provide a medium modulus. Additionally or alternatively, eachstrand 226 may be provided with first fibers 227 comingled with secondfibers 227, whereby the second fibers 227 have one or more of adifferent length, thickness, melting temperature, and/or Young's modulusthan the first fibers 227. For example, the strand 226 may include aplurality of carbon fibers 227 and a plurality of polymeric resin fibers227 that, when activated, solidify and hold the carbon fibers 227 in adesired shape and position relative to one another.

As used herein, the substrate 228 refers to any one of a veil, carrier,or backer to which at least one strand 226 of fibers 227 is attached.The substrate 228 may be formed from a thermoset polymeric material or athermoplastic polymeric material and can be a textile (e.g., knit,woven, or non-woven), an injection molded article, an organosheet, or athermoformed article.

The strands 226 of fibers 227 forming the plies 223, 224 of each layer221, 222 may be affixed to the same or separate substrates 228 andembroidered in a layered configuration. If the strands 226 of fibers 227are applied to separate substrates 228, the individual substrates 228are stacked on top of one another once each substrate 228 is suppliedwith a strand 226 of fibers 227. If, on the other hand, only onesubstrate 228 is utilized in forming the outsole plate 214, a firststrand 226 of fibers 227 is applied to the substrate 228 with additionalstrands 226 of fibers 227 (i.e., layers) being applied on top of thefirst strand 226. Finally, a single, continuous strand 226 of fibers 227may be used to form the outsole plate 214, whereby the strand 226 isinitially applied and affixed to the substrate 228 and is subsequentlylayered on top of itself to form a layered construction.

When forming the layers 221, 222 of the outsole plate 214, the strand orstrands 226 of the plies 223, 224 may be applied directly to thesubstrate 228, and may be attached to the substrate 228 using stitching230 to hold the strands 226 in a desired location. In some examples, thestitching 230 may include a continuous zig-zag stitch extending alongthe strand. Alternatively, the stitching 230 may be provided at discreteattachment points spaced along the strand 226.

The stitching 230 may be formed from the same material as the substrate228. Alternatively, the stitching 230 may be formed from a differentmaterial than the material forming the substrate 228 such that thestitching 230 is associated with a higher melting point than thesubstrate 228. Providing the stitching 230 with a higher melting pointthan the substrate 228 allows the stitching 230 to melt after thesubstrate 228 when heat is applied during formation of the outsole plate214. In some examples, the stitching 230, or at least a portion thereof,is formed from a thermoplastic material.

With reference to FIGS. 5A, 6A, 7, and 8, the lower layer 221 of theillustrated example includes a substrate 228, 228 a positioned on top ofthe lower layer 221, a first support ply 223 e adjacent to and beneaththe substrate 228 b, and a second support ply 223 c beneath the firstsupport ply 223 e. With the illustrated example, both of the supportplies 223 c, 223 e are beneath the substrate 228 b and are attached tothe substrate 228 b using a single “pass” of stitching 230, whereby eachstitch 230 secures both plies 223 c, 223 e. However, as discussed above,the first support ply 223 e may be stitched to the substrate 228 bseparately from the second support ply 223 c. Further, although supportplies 223 c, 223 e having strands 226 extending transverse to each otherare illustrated, any combination of the support plies 223 a-223 edescribed below may be used in the lower layer 221.

Referring to FIGS. 9A-9E, several examples of configurations of thesupport plies 223 are shown. As shown, the support plies 223 of theoutsole plate 214 each include at least one support ply strand 226, 226a wound in a uniform serpentine configuration, such that the support plystrands 226 a each include a plurality of linear segments 232 arrangedin parallel. Each of the segments 232 is straight and is connected toadjacent ones of the segments 232 by loops 234 at each end. In someexamples, the support ply strands 226 a may be tightly wound, wherebyeach segment 232 abuts an adjacent one of the segments 232 to provide asubstantially continuous layer of the support ply strands 226 a. In someexamples, the support ply strands 226 a may be wound loosely, wherebyadjacent segments 232 are separated from each other by a gap (notshown). In some examples, the segments 232 may be equally spaced fromeach other. However, spacing between segments 232 may be variable, suchthat some segments are spaced farther apart from each other than others.Additionally, some segments 232 may be spaced apart from each other,while other segments 232 abut each other.

As shown in FIGS. 9A-9E, the segments 232 may extend parallel to or atan oblique angle Φ to the longitudinal axis A_(F). For example, alongitudinal axis A_(S) of the segments 232 may extend at oblique anglesto the longitudinal axis A_(F) ranging from −30 degrees (−30°) to 30degrees (30°). In one example, the segments 232 may be oriented at +/−30degrees (30°) relative to a longitudinal axis A_(F) of the article offootwear 10, as shown in FIGS. 9C and 9E. In another example, thesegments 232 of the support ply strand 226 a may be arranged at an angleΦ of +/−15 degrees (15°) relative to a longitudinal axis A_(F) of thearticle of footwear 10, as shown in FIGS. 9B and 9D. Other angles may beselected to impart desired stiffness to the outsole plate 214.

As introduced above, the lower layer 221 includes a plurality ofapertures 225 formed therethrough. Each of the apertures 225 isconfigured to receive a portion of one of the traction elements 216therethrough when the components 216, 218, 221, 222 of the outsole plate214 are assembled prior to molding. As shown in FIG. 7, the apertures225 may be formed through the substrate 228 a and each of the supportplies 223. As discussed above, the substrate 228 a is formed of asubstantially continuous sheet of material. Accordingly, the apertures225 may be formed in the substrate 228 a by material removal methods,such as cutting or punching. Conversely, the apertures 225 are formedthrough the support plies 223 by stitching adjacent segments 232 of thesupport ply strands 226 a of each support ply 223 to be spaced apartfrom each other in discrete areas of the lower layer 221. As shown inFIG. 7, the lower layer 221 may include an increased density ofstitching 230 around each of the apertures 225 so that the segments 232follow an arcuate path to define an outer periphery of the aperture 225.Accordingly, a first one of the apertures 225 is defined by (i) anopening that is cut or punched through the material of the substrate 228a, (ii) a first space between two adjacent segments 232 of a support plystrands 226 a of a first one of the plies 223, and (iii) a second spacebetween two adjacent support ply strands 226 a of a second one of theplies 223, whereby each of the opening, the first space, and the secondspace are in communication with each other and cooperate to define anuninterrupted passage through the lower layer 221. Additional openingsor spaces may be formed where additional substrates 228 or plies 223,224 are included in the lower layer 221.

Turning now to FIGS. 5A, 6A, and 10-11G, example configurations of theupper layer 222 are provided. In addition to support plies 223 describedabove, the upper layer 222 of the outsole plate 214 further includes oneor more torsion plies 224. Unlike the support plies 223, which have asubstantially continuous and homogenous arrangement of adjacently-laidelongate segments 232 of support ply strands 226 a, the torsion plies224 are formed from torsion strands 226 b arranged in irregular patternsto impart anisotropic stiffness and gradient load paths throughout theoutsole plate 214.

The torsion plies 224 may further include peripheral strands 226 cinterweaved with the torsion strands 226 b along an outer perimeter ofthe torsion plies 224, whereby the peripheral strands 226 c areconfigured to define an outer peripheral edge P of the torsion plies 224when the torsion strands 226 b are trimmed, as described below.Accordingly, the peripheral strand 226 c of each of the torsion plies224 may advantageously provide a continuous boundary of the outsoleplate 214. The continuous peripheral strand 226 c provides improvedstrength along peripheral edge P of the outsole plate 214, and minimizesexposed ends of the trimmed torsion strands 226 b.

With reference to FIGS. 5A, 6A, and 10, the upper layer 222 includes oneof the substrates 228, 228 b defining a base of the upper layer 222 forreceiving a plurality of the plies 223, 224. The plies 223, 224 of theupper layer 222 include a first support ply 223, 223 c stacked adjacentto the substrate 228 b, a pair of torsion plies 224, 224 a stacked inseries atop the first support ply 223, 223 c, and a second support ply223, 223 e disposed on an opposite side of the upper layer 222 from thesubstrate 228 b. Thus, the upper layer 222 is arranged such the torsionplies 224 are interposed between the support plies 223. Although theillustrated upper layer 221 includes two torsion plies 224, 224 a havingthe same configuration, any one of the examples of the torsion plies 224a-224 g described below may be used. Additionally or alternatively,different combinations of the torsion plies 224, 224 a-224 g may beinterposed between different combinations of the support plies 223, 223a-223 e.

Referring to FIGS. 11A-11G, the torsion plies 224 of the outsole plate214 each include at least one torsion strand 226, 226 b wound in an anon-uniform, serpentine configuration, such that each torsion strand 226b includes a plurality of arcuate segments 236 distributedanisotropically throughout the ply 224, 224 a-224 g. With reference toFIGS. 11A-11G each of the segments 236 includes arcuate portions and isinitially connected to adjacent ones of the segments 236 by loops 238 ateach end. Unlike the support plies 223, which have a plurality oflinear, uniformly distributed segments, the segments 236 of the torsionplies 224 include arcuate portions, and are variably spaced apart fromeach other.

The torsion strands 226 b of the torsion plies 224 may include aplurality of medial segments 236 a, a plurality of lateral segments 236b, and/or a plurality of interior segments 236 c. As shown, the segments236 a-236 c are generally arranged in a splayed pattern such that anaverage spacing between the segments 236 a-236 c is greater in theforefoot region 12 and the heel region 16 than it is in the mid-footregion 14. For instance, in the example of FIGS. 11A-11G, the segments236 a are tightly spaced through the mid-foot region 14, and divergefrom each other along a direction from the mid-foot region 14 towardseach of the anterior end 18 and the posterior end 20. Due to the spacingbetween adjacent segments 236 a-236 c of the torsion strand 226 b beingcloser in the mid-foot region 14 compared to the spacing in the forefootand heel regions 12, 16, respectively, the segments 236 a-236 ccollectively provide a greater concentration/density of fibers 227 inthe mid-foot region 14 compared to the concentration/density of fibers227 in the forefoot and heel regions 12, 16, respectively. Accordingly,the torsion strands 226 b of the torsion plies 224, 224 a-224 g mayprovide the outsole plate 214 with a stiffness in the mid-foot region 14that is greater than the stiffness of the outsole plate 214 in each ofthe forefoot region 12 and the heel region 16.

As discussed below, the ends 240, 241 of adjacent ones of the segments236 a-236 c may be initially connected to each other by loops 238 suchthat a single torsion strand 226 b forms the medial segments 236 a, thelateral segments 236 b, and the interior segments 236 c. In the examplesof FIGS. 11A-11D, the torsion strand 226 b includes the loops 238disposed outside a peripheral edge P of the torsion ply 224, 224 a forconnecting adjacent segments 236 a-236 c of the torsion strand 226 b. Asdiscussed above, the peripheral edge P is defined by a peripheral strand226 c extending along an outer perimeter of the ply 224, 224 a. Theperipheral strand 226 c may be interweaved through the segments 236 ofthe torsion strand 226 b.

To eliminate the presence of pinch points when subjecting the torsionplies 224 to pressure (e.g., molding) to form the outsole plate 214, thetorsion strand 226 b may be trimmed along the peripheral strand 226 c toform a continuous peripheral edge P of the torsion ply 224. Withreference to the examples of the torsion plies 224, 224 e-224 g shown inFIGS. 11E-11G, the torsion strands 226 b may be contained within theperipheral edge P of the ply 224, 224 e-224 g. Here, the loops 238 maybe consolidated when the strands 226 and other plies 223, 224 aresubjected to heat and pressure to consolidate the fibers 227, andthereby form the outsole plate 214.

Referring to FIG. 11A, in one example of the torsion ply 224, 224 a atorsion strand 226 b is wound continuously in an overlapping pattern,whereby a medial segments 236 a extend from the medial side 22 in theforefoot region 12 to the lateral side 24 in the heel region 16. Each ofthe medial segments 236 a then wraps around the heel region 16 to themedial side 22, and transitions into a corresponding lateral segment 236b that extends from the medial side 22 in the heel region 16 to thelateral side 24 in the forefoot region 12. As discussed above, each oflateral segments 236 b extends beyond the peripheral strand 226 c in theforefoot region 12. A loop 238 is formed where the strand lateralsegment 236 b is turned back towards the peripheral strand 226 c toextend back towards the medial side 22 in the heel region 16, around theheel region 16 to the lateral side 24, and back to the medial side 22 inthe forefoot region 12, where another loop 238 is formed. This patternis continued until the segments 236, 236 a-236 c are distributed alongan entirety of the ply 223, 223 from the medial side 22 to the lateralside 24. In some examples, the medial segments 236 a, the lateralsegments 236 b, and the interior segments 236 c may alternatinglyinterweave or overlap each other as the torsion strand 226 b is laid,thereby forming a basket weave configuration in the mid foot region 14.Additionally or alternatively, all of the medial segments 236 a may belaid above or beneath all of the lateral segments 236 b.

In another example of a torsion ply 224, 224 b—shown in FIG. 11B—thetorsion strand 226 b is arranged such that the segments 236, 236 a-236 cextend generally along a longitudinal axis A_(F) of the article offootwear 10. The medial segments 236 a are generally disposed on themedial side 22 of the torsion ply 224, 224 b and extend from first ends240 a at the medial side 22 in the forefoot region 12 to second ends 241a at the medial side 22 in the heel region 16. One or more of the medialsegments 236 a have a reverse curve shape, such that each of the medialsegments 236 a curves towards the lateral side 24 through the forefootregion 12 and curves towards the medial side through the mid-foot region14 and/or the heel region 16.

The lateral segments 236 b are generally disposed on the lateral side 24of the torsion ply 224 b and extend from first ends 240 c at the lateralside 24 in the forefoot region 12 to second ends 241 c at the medialside 22 in the heel region 16. The lateral segments 236 b each extendalong a simple or compound curve from the first ends 240 c to the secondends 241 c. Accordingly, the lateral segments 236 b may be described asbeing “C-shaped.”

The interior segments 236 c are generally disposed intermediate themedial side 22 and the lateral side 24 and extend from first ends 240 bat the anterior end 18 to second ends 241 b at the posterior end 20. Oneor more of the interior segments 236 c have a reverse curved shape, suchthat each of the segments curves towards the lateral side 24 in theforefoot region 12, is substantially straight through the mid-footregion 14, and curves towards the medial side 22 through the heel region16. Accordingly, the interior segments 236 c may be described as being“S-shaped.”

Referring to the example of the torsion ply 224, 224 c shown in FIG.11C, the torsion strand 226 b may be formed from a continuous strand 226of fibers 227 or two or more strands 226 of fibers 227. As shown, thetorsion strand 226 b of the torsion ply 224, 224 c includes loops 238disposed outside the peripheral strand 226 c of the ply 224, 224 c forconnecting adjacent segments 236, 236 a, 236 b of the torsion strand 226b.

The torsion strand 226 b includes a plurality of medial segments 236 aand a plurality of lateral segments 236 b that interweave or overlapwithin an interior region 242 of the ply 224 c. As shown, the interiorregion 242 is formed in the midfoot region 14 and is spaced inwardlyfrom each of the medial side 22 and the lateral side 24.

The medial segments 236 a may be disposed adjacent and substantiallyparallel to one another, whereby each medial segment 236 a has a lengththat extends between a first end 240 a proximate to the peripheralstrand 226 c at the medial side 22 in the forefoot region 12, and asecond end 241 a proximate to the peripheral strand 226 c at the lateralside 124 in the heel region 16. The medial segments 236 a traverse theply 224 c in the shape of a reverse “C”, whereby an intermediate portionof each of the medial segments 236 a passes through the interior region242. Here, the portions of the medial segments 236 a in the midfootregion 14 extend in a direction substantially parallel to thelongitudinal axis A_(F) of the article of footwear 10. In someimplementations, the spacing between each adjacent medial segment 236 ais substantially uniform across the lengths of the medial segments 236a.

On the other hand, each lateral segment 236 b has a corresponding lengththat extends between a first end 240 b proximate to the peripheralstrand 226 c at the lateral side 24 in the forefoot region 12, and asecond end 241 b proximate to the peripheral strand 226 c at the lateralside 24 in the heel region 16. The shape of the lateral segments 236 bare inverted relative to the shape of the medial segments 236 a, andtherefore traverse the ply 224 c in the shape of a “C”, whereby anintermediate portion of each of the lateral segments 236 b passesthrough the interior region 242. Here, the portions of the lateralsegments 236 b in the midfoot region 14 extend in a directionsubstantially parallel to the longitudinal axis A_(F) of the article offootwear 10.

The medial segments 236 a extending into and out of the interior region242 may cross-cross, overlap, and/or interweave with one or more of thelateral segments 236 b extending into and out of the interior region242. While the spacing between each adjacent medial segment 236 a may besubstantially uniform across the lengths of the medial segments 236 a,each medial segment 236 a may be disposed between two correspondinglateral segments 236 b in an alternating fashion within the interiorregion 242. Accordingly, the medial segments 236 a and the lateralsegments 236 b of the torsion ply 224 c may extend substantiallyparallel to the longitudinal axis A_(F) within the interior region 242and diverge away from one another when extending toward their respectiveends at one of the lateral and medial sides 22, 24, respectively. Insome implementations, the example of the torsion ply 224 c provides theupper layer 222 with a greater concentration/density of fibers 227within the interior region 242 compared to the concentration/density offibers outside the interior region 242, thereby increasing the stiffnessof the outsole plate 214 within the interior region 242.

As shown in FIG. 11C, the torsion ply 224 c includes a void 243, 243 ain the forefoot region 12 and a void 243, 243 b in the heel region 16where the fibers 227 are absent. In some examples, the voids 243 exposeone or more plies 223, 224 or substrates 228 situated adjacent to thetorsion ply 224 c. When incorporated in a layered configuration to formthe layers 221, 222, the torsion ply 224 c does not impart any stiffnessproperties in the areas of the forefoot region 12 and the heel region 16where the voids 243 a, 243 b are formed.

FIG. 11D provides a top view of another example of a torsion ply 224,224 d that may be used in one of the layers 221, 222. The pattern of thetorsion strand 226 b is shown relative to a peripheral edge P of thefinished outsole plate 214, which may be defined by a peripheral strand226 c. As with the previous examples of torsion plies 224, the torsionply 224, 224 d may be formed from a corresponding continuous torsionstrand 226 b or two or more torsion strands 226 b, and may include atleast one of carbon fibers, aramid fibers, boron fibers, glass fibers,and polymer fibers. FIG. 11D shows the torsion ply 224 d includingcorresponding loops 238 for connecting adjacent segments 236, 236 a-236c of the torsion strand 226 b. The loops 238 disposed in the forefootregion 12 are disposed inside the peripheral strand 226 c, while theloops 238 proximate to the heel region 16 are disposed outside theperipheral strand 226 c. To eliminate the presence of pinch points whensubjecting the torsion ply 224 d to pressure (e.g., molding) to form theoutsole plate 214, the loops 238 proximate to the heel region 16 are cutalong the peripheral strand 226 c to remove the presence of loops 238extending outside the peripheral strand 226 c.

Compared to examples of the torsion plies 224, 224 a-224 c describedabove, the torsion ply 224 d of FIG. 11D provides a greater variance instiffness across the length of the outsole plate 214. Interior segments236 c of the ply 224 d extend substantially parallel to the longitudinalaxis A_(F) from the heel region 16 to the midfoot region 14, whilesegments along the lateral side 22 and the medial side 24 convergetoward the interior region 242 of the outsole plate 214 when extendingfrom the heel region 16 to the midfoot region 14. As a result, thetorsion ply 224 d includes a spacing between adjacent segments 236, 236a-236 c in the heel region 16 that decreases as the segments 236, 236a-236 c extend into the midfoot region 14, whereby the midfoot region 14of the outsole plate 214 is associated with greater density of fibers227 than the heel region 16.

In some configurations, the segments 236 disperse into four discretegroups of segments 236 when extending from the midfoot region 14 to thefirst ends 240 disposed in the forefoot region 12 of the torsion ply 224d. For instance, a group of medial segments 236 a generally follows theperipheral strand 226 c of the torsion ply 224 d at the medial side 22,while a group of lateral segments 236 b generally follows the peripheralstrand 226 c of the torsion ply 224 d at the lateral side 24. Moreover,a first group of interior segments 236 c is disposed adjacent and spacedinward from the group of the medial segments 236 a, and a second groupof interior segments 236 c is disposed adjacent and spaced inward fromthe group of the lateral segments 236 b. In the example shown, the firstand second groups of interior segments 236 c are also spaced apart fromone another. Accordingly, the torsion ply 224 d includes multiple voids243 c between the groups of segments 236 where the fibers 227 areabsent, thereby exposing one or more plies 223, 224 or substrates 228that may be situated adjacent to the torsion ply 224 d in the forefootregion 12. Here, the layer 221, 222 associated with the torsion ply 224d does not impart any stiffness properties in the areas of the forefootregion 12 where the presence of fibers 227 are absent. Each group ofsegments 236 corresponds to a respective “tendon” imparting stiffnessproperties based on the number of segments and/or spacing betweenadjacent segments in each discrete group. More specifically, thediscrete groups of segments 236 cooperate to impart anisotropicstiffness and gradient load paths through the forefoot region 12 of theoutsole plate 214. For instance, the longitudinal stiffness and thetransverse stiffness taken at different locations in the forefoot region12 may alternate between some magnitude of stiffness provided by theconcentration fibers 227 in the corresponding group and no stiffnesswhere the presence of fibers 227 is absent.

In some examples, the medial segments 236 a are shorter than the firstgroup of interior segments 236 c adjacent to the medial segments 236 a,the first group of interior segments 236 c are shorter than the secondgroup of interior segments 236 c adjacent to the lateral segments 236 b,and the second group of interior segments 236 c are longer than thegroup of lateral segments 236 b. In some configurations, at least one ofthe groups of segments 236 includes a different number of segments 236than the other groups. In other configurations, each group of segmentsincludes the same number of segments 236 as the other groups. Increasingthe number of segments 236 in a corresponding group provides a greaterconcentration of fibers 227 and, thus, imparts a greater stiffness forthe corresponding group.

In some implementations, the spacing between adjacent segments 236 in atleast one of the groups varies across the length of the torsion ply 224d between the midfoot region 14 and the first ends 240 in the forefootregion 12. For instance, the spacing between adjacent segments 236 in atleast one of the groups may increase as the segments 236 traverse intothe forefoot region 12 from the midfoot region 14, and then the spacingmay gradually decrease until the segments terminate at the correspondingloops 238 in the forefoot region 12. In other implementations, thespacing between adjacent segments 236 in at least one of the groups issubstantially uniform across the length of the torsion ply 224 d betweenthe midfoot region 14 and the loops 238 in the forefoot region 12.

Due to the spacing between adjacent segments 236 of the torsion ply 224d being closer in the midfoot region 14 compared to the spacing in theheel region 16, the torsion ply 224 b collectively provides a greaterconcentration/density of fibers 227 in the midfoot region 14 compared tothe concentration/density of fibers 227 in the heel region 16. Moreover,due to the segments 236 branching out into four discrete groups whiletraversing the torsion ply 224 d from the midfoot region 14 to theforefoot region 12, the concentration/density of fibers 227 in themidfoot region 14 is greater than the density of fibers 227 in theforefoot region 12 where the fibers 227 are absent in the voids 243 cbetween each discrete group of segments 236. Accordingly, the torsionply 224 d imparts different stiffness properties to the outsole plate214 in each of the forefoot, midfoot, and heel region 12, 14, 16,respectively.

FIG. 11E shows another example of a torsion ply 224, 224 e that may beused in the layers 221, 222. The pattern of the torsion strand 226 isshown relative to a peripheral edge P of the finished outsole plate 214.The torsion ply 224 e is substantially similar to the torsion ply 224 dshown in FIG. 11D, except that segments 236, 236 a-236 c of fibers 227are shorter than the corresponding segments 236, 236 a-236 c of thetorsion ply 224 d. For instance, the torsion ply 224 e includes segments236 having a shortened length, whereby fibers 227 are absent in amajority of both the forefoot region 12 and the heel region 16.

The interior segments 236 c of the torsion ply 224 e extendsubstantially parallel to the longitudinal axis A_(F) from correspondingloops 238 disposed in the heel region 16, while segments 236 a, 236 bcloser to the medial side 22 and the lateral side 24 converge toward theinterior region 242 of the footwear when extending from thecorresponding loops 238 disposed in the heel region 16. However, incontrast to the torsion ply 224 d having adjacent segments 236 thatextend across the width of the midfoot region 14, the segments 236forming the torsion ply 224 e are concentrated toward the interiorregion of the torsion ply 224 e within the midfoot region 14, whiledefining gaps along the peripheral edge P where the fibers 227 areabsent and, thus, not imparting stiffness.

Similar to the torsion ply 224 d, the segments 236 of the torsion ply224 e also disperse into four discrete groups of segments 236 whenextending from the midfoot region 14 to the loops 238 disposed in atleast one of the forefoot region 12 or the midfoot region 14. Forinstance, a group of medial segments 236 a generally follows theperipheral strand 226 c of the torsion ply 224 d at the medial side 22and terminate in the forefoot region 12, while a group of lateralsegments 236 b generally follows the peripheral strand 226 c of thetorsion ply 224 d at the lateral side 24 and terminate in the midfootregion 14. Moreover, a first group of interior segments 236 c isadjacent and spaced inward from the group of medial segments 236 a, anda second group of interior segments 236 c is adjacent and spaced inwardfrom the group of the lateral segments 236 b. Accordingly, the torsionply 224 e includes multiple voids 243 d between the groups of segments236 where the fibers 227 are absent, thereby exposing one or more plies223, 224 or substrates 228 that may be situated adjacent to the torsionply 224 d in the forefoot region 12. Here, torsion ply 224 e does notimpart any stiffness properties in the voids 243 d in the forefootregion 12 between the groups of segments 236. However, the discretegroups of segments 236 cooperate to impart anisotropic stiffness andgradient load paths in regions extending toward the forefoot region 12and away from the high concentration/density of fibers 227 in themidfoot region 14, where the magnitude of stiffness is greatest.

In some examples, the group of medial segments 236 a are shorter thanthe first group of interior segments 236 c, the first group of interiorsegments 236 c are shorter than the second group of interior segments236 c, and the second group of interior segments 236 c are shorter thanthe group of lateral segments 236 b. In some configurations, at leastone of the groups of segments 236 includes a different number ofsegments 236 than the other groups. In other configurations, each groupof segments 236 includes the same number of segments 236 as the othergroups. Increasing the number of segments 236 in a corresponding groupprovides a greater concentration of fibers 227 and, thus, imparts agreater stiffness for the corresponding group. Additionally, the spacingbetween adjacent segments 236 in at least one of the groups may vary ormay be substantially uniform as the segments traverse toward theforefoot region 12 of the torsion ply 224 e. For instance, the spacingbetween segments 236 in at least one of the groups may initiallyincrease as the segments begin to traverse toward the forefoot region 12from the midfoot region 14, and then the spacing may gradually decreaseuntil the segments 236 terminate at the corresponding loops 238 in theforefoot region 12 or in the midfoot region 14 at a location proximateto the forefoot region 12.

FIG. 11F provides a top view of a fifth example of a torsion ply 224 fthat may be used in either of the layers 221, 222. The pattern of thetorsion strand 226 b of the torsion ply 224 f is shown relative to aperipheral edge P of the finished outsole plate 214. The torsion ply 224f may be formed from one continuous torsion strand 226 b or from two ormore strands 226 of fibers 227.

FIG. 11F shows the torsion ply 224 f having a plurality of segments 236having the same length extending between a first location L₁ disposed inthe forefoot region 12 and a second location L₂ disposed in the heelregion 16. The torsion strand 226 b includes loops 238 disposed at thefirst location L₁ and the second location L₂ for connecting adjacentsegments 236. In the example shown, the segments 236 a proximate to themedial side 22 of the ply 224 f converge toward the interior of the ply224 f when extending from the second location L₂ toward the medialregion 14, and then diverge and fan out away from the interior of theply 224 f when extending from the medial region 14 to the first locationL₁. Thus, the segments 236 a proximate the medial side 22 generallyfollow the curvature of the peripheral strand 226 c of the torsion ply224 f at the medial side 22. Conversely, the segments 236 b of thetorsion ply 224 f proximate to the lateral side 24 of the ply 224 f andwithin the interior of the outsole plate 214 extend substantiallyparallel to one another and substantially parallel to the longitudinalaxis A_(F) between the first location L₁ and the second location L₂. Theconverging by the segments 236 a proximate to the medial side 22 intothe interior of the torsion ply 224 f causes the spacing betweenadjacent segments 236 a in the medial region 14 of the plate to decreaseand, thus, provide a greater magnitude of stiffness in the midfootregion 14 due to the corresponding increase in the concentration/densityof fibers 227. Moreover, the spacing between each adjacent segment 236of the torsion ply 224 f is greater in the forefoot region 12 proximateto the first location L₁ compared to the spacing between each adjacentsegment 236 a in the heel region 16 proximate to the second location L₂.Accordingly, the torsion ply 224 f provides the heel region 16 with amagnitude of stiffness that is less than the magnitude of stiffness inthe midfoot region 14 and greater than the magnitude of stiffness in theforefoot region 12. In other configurations, the spacing between eachadjacent segment 236 of the torsion ply 224 f is substantially uniformacross the lengths of the segments 236 between the first location L₁ andthe second location L₂.

FIG. 11G provides a top view of a sixth example of a configuration of atorsion ply 224 g that may be used in the layers 221, 222 of the outsoleplate 214. The pattern of the sixth example of the torsion ply 224 g isshown relative to a peripheral edge P of the finished outsole plate 214.In the example shown, torsion ply 224 g is formed from one continuoustorsion strand 226 b. However, in other examples, the torsion ply 224 gmay be formed from two or more strands 226 of fibers 227.

FIG. 11G shows a torsion strand 226 b of the torsion ply 224f having aplurality of segments 236, 236 a-236 c that each extend along the lengthof the ply 224 f from a first location L₁ disposed in the heel region 16to a corresponding second, third, and fourth locations L₂, L₃, L₄disposed in the forefoot region 12 of the outsole plate 214. Forinstance, lateral segments 236 b extend between the first location L₁and the corresponding second location L₂, while medial segments 236 aextend between the first location L₁ and the corresponding fourthlocation L₄ disposed closer to the first end 210 of the outsole plate214 than the second location L₂ corresponding to the lateral segments236 b. Additionally, interior segments 236 c disposed between the medialsegments 236 a and the lateral segments 236 b extend between the firstlocation L₁ and the corresponding third location L₃. In the exampleshown, the third location L₃ corresponding to the interior segments 236c is disposed closer to the first end 210 of the outsole plate 214 thanthe second location L₂ corresponding to the lateral segments 236 b andfurther away from the first end 210 of the outsole plate 214 than thefourth location L₄ corresponding to the medial segments 236 a. Thetorsion strand 226 b includes loops 238 disposed at each location L₁-L₄for connecting adjacent segments 236 of the torsion ply 224 f

In some implementations, the corresponding second, third, and fourthlocations L₂, L₃, L₄ cooperate to define a terminal end the torsion ply224 f in the forefoot region 12 that aligns with an anatomical featureof the foot when the foot is received upon the outsole plate 214 withinthe article of footwear 10. In some examples, the anatomical featureincludes a bend line of all the toes of the foot. The bend line mayextend through the metatarsal-phalangeal (MTP) joints of the foot whereproximal phalanges of the toes meet corresponding metatarsals of thefoot. Accordingly, each segment 236 may impart stiffness to the outsoleplate 214 under the wearer's foot up to the MTP joints without impartingany stiffness in areas of the outsole plate 214 where the toes of thefoot reside to provide desirable flexibility during athletic movements.

The medial segments 236 a may be disposed adjacent and substantiallyparallel to one another along the longitudinal axis A_(F) of the outsoleplate 214 proximate to the peripheral strand 226 c at the medial side22. In some examples, the spacing between each adjacent medial segment236 a is substantially uniform across the length of the medial segments236 a between the first location 479 and the fourth location L₄. Inother examples, the spacing between each adjacent medial segment 236 avaries across the length such that the spacing between each adjacentmedial segment 236 a is closer within the midfoot region 14 compared tothe spacing within the forefoot and heel regions 12, 16, respectively.

The lateral segments 236 b may be disposed adjacent and substantiallyparallel to one another along the longitudinal axis A_(F) of the outsoleplate 214 proximate to the peripheral strand 226 c at the lateral side24. In some examples, the spacing between each adjacent lateral segment236 b is substantially uniform across the length of the lateral segments236 b between the first location L₁ and the second location L₂. In otherexamples, the spacing between each adjacent lateral segment 236 b variesacross the length such that the spacing between each adjacent lateralsegment 236 b is closer within the midfoot region 14 compared to thespacing within the forefoot and heel regions 12, 16, respectively.Providing a narrower spacing between adjacent segments offers a greaterconcentration/density of fibers 227 to thereby increase the stiffness ofthe outsole plate 214.

Within interior regions of the outsole plate 214, the interior segments236 c may be disposed adjacent and substantially parallel to one anotheralong the longitudinal axis A_(F) of the outsole plate 214. As with themedial segments 236 a and the lateral segments 236 b, the spacingbetween each adjacent interior segment 236 c may be substantiallyuniform or may vary across the length of the interior segments 236 cbetween the first location L₁ and the third location L₃.

In some configurations, the segments 236 a-236 c of the torsion ply 224g are disposed adjacent and substantially parallel to one another withinthe midfoot and heel regions 14, 16, respectively, and then dispersefrom one another when extending from the midfoot region 14 to each ofthe corresponding second, third, and fourth locations L₂, L₃, L₄disposed in the forefoot region 12. For instance, the medial segments236 a may generally follow the contour of the peripheral strand 226 c ofthe torsion ply 224 g at the medial side 22, the lateral segments 236 bmay generally follow the contour of the peripheral strand 226 c of thetorsion ply 224 g at the lateral side 24, and the interior segments 236c may extend substantially parallel to the longitudinal axis A_(F) asthe lateral and medial segments 236 a, 236 b diverge outward and awayfrom the interior segments 236 c. Here, the torsion ply 224 f does notimpart any stiffness properties in the voids 243 d in the forefootregion 12 between the segments 236, 236 a-236 c where the fibers 227 areabsent. However, the dispersing of the segments 236, 236 a-236 c of thetorsion ply 224 g imparts anisotropic stiffness and gradient load pathsin regions extending into the forefoot region 12 and away from the highconcentration/density of fibers 450 in the midfoot region 14, whereatthe magnitude of stiffness is highest.

As set forth above, one or more of at least one of the torsion plies224, 224 a-224 g of FIGS. 11A-11G may be incorporated into upper layer222 or the lower layer 221 to tune stiffness properties imparted by thefinished outsole plate 214.

With continued reference FIGS. 3-6B, the first traction elements 216include a flange 244 and a ground-engaging projection 246 extending fromthe flange 244. In one example, the flange 244 is substantiallycylindrical in shape, and may include a plurality of notches orapertures formed through a thickness thereof. In some examples, theflange 244 may include a plurality of radially-arranged tabs or notchesconfigured to engage the components 220, 222, 223 of the outsole plate214 (i.e. layers 221, 222 and resin 220) to prevent rotation of thefirst traction elements 216 within the outsole plate 214. The projection246 extends axially from the flange 244, and may taper in width along adirection from the flange 244 to a distal end. As shown, the projection246 is conical in shape. However, the projection 246 may be pyramidal,or have other geometries.

As shown in FIGS. 5A-6B, in one example the first traction element 216,216 a may be formed as a unitary body, whereby the flange 244, 244 a andthe projection 246, 246 a are integrally formed with each other.Additionally or alternatively, one or more of the first tractionelements 216, 216 b may be fragmentary, whereby the projection 246, 246b is configured to be removably attached to the flange 244, 244 b. Forexample, the flange 244, 244 b may be an anchor portion having a firstcleat-retention feature 247 a and the projection 246, 246 b may be aseparately-formed cleat having a second cleat-retention feature 247 bconfigured to cooperate with the first cleat-retention feature 247 a ofthe flange 244, 244 b. In one example, the first cleat-retention feature247 a may be a female-threaded bushing, while the second cleat-retentionfeature 247 b is a male-threaded stud. Accordingly, the differentprojections 246 can be attached to the flange 244 to provide desiredtraction characteristics to the outsole 204. The outsole 204 may includeonly unitary first traction elements 216 a, only fragmentary firsttraction elements 216 b, or a combination of unitary first tractionelements 216 a and fragmentary first traction elements 216 b.

In addition to the first traction elements 216, the outsole 204 may alsoinclude the ground-engaging assembly 218 including a plurality oftraction elements 248 interconnected with each other by respectiveconnecting members 250. As shown in FIGS. 12B-12F, the ground-engagingassembly may include a plurality of fasteners 252 extending therefrom,which are configured to engage one or more of the plies 223, 224 tosecure the ground-engaging assembly 218 to the outsole 204 prior tomolding.

As best shown in FIG. 4, the traction elements 248 of theground-engaging assembly 218 may be described as being chevron-shaped,and include a pair of wings 254 extending in opposite directions from acentral portion 256. In some examples, at least one of the wings 254 mayinclude a compound taper, whereby a width of the wing 254 tapers along afirst direction—parallel to the ground-engaging surface—from the centralportion 256 to a terminal end 258, and along a seconddirection—perpendicular to the ground-engaging surface—from a base 260to a distal edge 262.

As shown in FIGS. 12A-12F, the ground-engaging assembly 218, 218 a-218 fincludes one of the connecting members 250 extending between each pairof adjacent traction elements 248. Accordingly, each traction element248 may be connected to a plurality of adjacent traction elements 248 byrespective connecting members 250, such that the connecting members 250and the traction elements 248 form a web or network. For example, afirst one of the traction elements 248 may be connected to a second oneof the traction elements 248 by a first connecting member 250, andconnected to a third one of the traction elements 248 by a secondconnecting member 250. Thicknesses of the connecting members 250 may beselected to impart desired properties of strength and stability to theground-engaging assembly 218. For instance, the connecting members 250 aof the example of the ground-engaging assembly 218 a shown in FIG. 12Ahave a greater thickness than the connecting members 250 b-f of theexamples of the ground-engaging assembly shown in FIGS. 12B-12F.

In the illustrated example, the ground-engaging assembly 218 includes acontinuous network of connecting members 250 and traction elements 248extending along an entire length of the outsole 204. However, in otherexamples, the ground-engaging assembly 218 may be fragmentary, andinclude a first sub-network of traction elements 248 and connectingmembers 250 disposed in a first region 12, 14, 16 and a separatelyformed, second sub-network of traction elements 248 and connectingmembers 250 disposed in a second region 12, 14, 16.

As provided above, in some examples, the ground-engaging assembly 218,218 b-218 f further includes a plurality of the fasteners 252 configuredto engage one or more of the plies 223, 224 to secure theground-engaging assembly 218 to the layers 221, 222 during assembly ofthe outsole 204, as discussed below. The fasteners 252 project from theconnecting members 250 in an opposite direction from the tractionelements 248. As shown in FIGS. 12B-12F, some examples of the fasteners252 include a shaft 266 extending from one of the connecting members 250and a retention feature 268 disposed at a distal end of the shaft 266.

In a first example of the ground-engaging assembly 218, 218 b-218, theretention feature 268 of the fastener 252 b-252 e is an arm 268 a-268 dextending from the distal end of the shaft 266. In one example of thefastener 252 b, the arm 268 a may be curved to provide rounded,hook-shaped arms 268 b. In other examples of the fastener 252 c-252 e,the arm 268 c-268 e may be elongate and extend along a longitudinal axisat a relative angle to a longitudinal axis of the shaft 266. Forexample, a longitudinal axis of the arm 268 c may be arranged at anacute angle with respect to a longitudinal axis of the shaft 266 toprovide a hook-shaped retention feature 268 c having a tapered or flaredprofile for being inserted through the plies 223, 224 to capture one ormore of the strands 226. In other examples, the longitudinal axis of thearm 268 d may be perpendicular to the longitudinal axis of the shaft266. Additionally or alternatively, the longitudinal axis of the arm 268e may extend at an obtuse angle with respect to the longitudinal axis ofthe shaft 266, whereby the arm 268 e extends away from traction elements248.

In another example of the ground-engaging assembly 218, 218 f, theretention feature 268 is an anchor 268 f disposed at the distal end ofthe shaft 266. For example, the anchor 268 f may include a body having agreater width than the shaft 266 so that the anchor 268 f engages one ormore of the strands 226 of the plies 222, 224 when the outsole 204 isassembled. In the illustrated example, the anchors 268 f are cylindricalor disc-shaped bodies having a greater diameter than the shaft 266.However, other shapes of anchors 268 f may be used, as desired. Althoughthe illustrated examples of the ground-engaging assembly 218, 218 b-218f each include a single type of the fastener 252, 252 b-252 f, someexamples may include multiple types of the fasteners 252, 252 b-252 f.For example, the ground-engaging assembly 218 may include some fasteners252 having arms 268 b-268 e and other fasteners 252 having anchors 268f, as shown in FIGS. 5A-6B.

The ground-engaging assembly 218 may be formed using additivemanufacturing methods, such as three-dimensional (3D) printing. Forexample, the ground-engaging assembly may be 3D printed of a polymericmaterial, such as nylon. By forming the ground-engaging assembly 218using a three-dimensional printing process, the traction elements 248,connecting members 250, and fasteners 252 can be easily modified fordifferent applications. Furthermore, the three-dimensional printingprocess allows the fasteners 252 to be formed with complex geometriesnot capable of being formed using traditional molding processes. Forexample, ground-engaging assemblies 218 having fasteners 252 that areformed with hook-shaped arms 268 a, 268 b or anchors 268 e are difficultto manufacture using traditional molding processes, as the arms 268 a,268 b and anchors 268 e may cause the ground-engaging assembly 218become to fixed within a mold cavity. Additionally, three-dimensionalprinting allows the traction elements 248 to be customized on anindividual basis to accommodate different users, sports, and playingsurfaces.

With particular reference to FIGS. 13A-13D, formation of the outsole 204is described in conjunction with a mold 1000. The mold 1000 includes anupper mold plate 1002 and a lower mold plate 1004. The mold plates 1002,1004 define a mold cavity 1006 having the desired shape of the outsole204 to allow the mold 1000 to impart the desired shape of the particularoutsole 204 to the plies 222, 224. The mold cavity 1006 may include oneor more fixtures 1008 for securing the first traction elements 216within the mold 1000. For example, the fixtures 1008 may be magnetic andinclude conical cavities for receiving the projections 246 of the firsttraction elements 216. The benefits of the retainers 1008 are twofold.First, the fixtures 1008 align the first traction elements 216 withinthe mold to ensure proper spacing and arrangement. Secondly, thefixtures 1008 secure the first traction elements 216 within the moldcavity 1006 when the resin 220 is introduced, and prevent the firsttraction elements 216 from floating within the resin 220.

Initially, each of the lower layer 221 and the upper layer 222 may befabricated using desired combinations of the substrates 228 and plies223, 224 discussed above. Once the layers 221, 222 are assembled, theloops 238 may be trimmed to provide a continuous outer peripheral edge Pof each layer 221, 222, as shown in FIG. 11A. In addition to fabricatingthe layers 221, 222, the lower layer 221 may be provided with the firsttraction elements 216.

With each of the layers 221, 222 fabricated, the first traction elements216, the ground-engaging assembly 218, lower layer 221, and the upperlayer 222 may be arranged and assembled to form a layup of the outsole204. In some examples, the components 216, 218, 221, 222 of the outsole204 may be assembled outside of the mold cavity 1006, and thenpositioned within the mold cavity 1006 as an assembly. Alternatively,the mold cavity 1006 may function as an assembly fixture, whereby thecomponents 216, 218, 221, 222 can be stacked within the mold cavity1006. For example, the lower mold plate 1004 may include featurescorresponding to the shapes of the traction elements 248 of theground-engaging assembly 218 so that the ground-engaging assembly 218can be positioned within the mold cavity 1006.

With continued reference to FIGS. 5A, 6A, and 11A, lower layer 221 isinitially stacked upon the ground-engaging assembly 218. In addition toproviding for handling of the ground-engaging assembly, the connectingmembers 250 may collectively provide a support bed for the layers 221,222. When present, the shafts 266 may be received through one or more ofthe plies 223, 224 such that the fasteners 252 of the ground-engagingassembly 218 engage a top side of at least one of the plies 223, 224 asthe lower layer 221 is stacked atop the ground-engaging assembly.Particularly, the fasteners 252 may become entangled with the fibers 227of one or more of the plies 223, 224 to secure the ground-engagingassembly to the plies 222, 224. A length of the shaft 266 of each of thefasteners 252 may be selected depending on a thickness of each of theplies 223, 224 and a desired engagement between the fasteners 252 andthe plies 223, 224. Accordingly, one or more of the fasteners 252 mayengage the support plies 223 of the lower layer 221. Additionally oralternatively, one or more of the fasteners may engage the plies 223,224 of the upper layer 222.

The first traction elements 216 may be provided to the outsole 204lay-up at any time prior to the upper layer 222, regardless of whetherthe outsole 204 is assembled outside of the mold cavity 1006 or insideof the mold cavity 1006. For example, the first traction elements 216may be provided to the apertures 225 of the lower layer 221 before orafter the lower layer 221 is stacked atop the ground-engaging assembly218. As discussed above, once the first traction elements 216 arereceived within the mold cavity 1006, the projections 246 of the firsttraction elements 216 are engaged by the fixtures 1008 formed in themold cavity 1006 to align and secure the first traction elements 216within the mold 1000.

As discussed above, in some examples the first traction elements 216 amay each be formed as unitary bodies having a flange 244 a and aprojection 246 a protruding from the flange 244 a. In thisconfiguration, the projection 246 of each of the first traction elements216 may be inserted through the apertures 225 of the lower layer 221 sothat the projections 246 are received through the substrate 228 a andthe strands 226, as shown in FIGS. 5A and 6A. Accordingly, theprojections 246 will project from the ground-engaging surface 208 of theoutsole 204. As the projections 246 of each of the first tractionelements 216 are inserted through the apertures 225, the flanges 244 ofeach of the first traction elements 216 engage or abut an upper surfaceof the substrate 228 a of the lower layer 221. In other examples, anupper surface of the lower layer 221 may be defined by one of the plies223, 224, and the flanges 244 of each of the first traction elements 216may abut or become entangled within the strands 226 of the plies 223,224. Additionally or alternatively, the outsole 204 may be constructedwith one or more of the fragmentary first traction elements 216 b,whereby the flange 244 b and the projection 246 b are provided tooutsole 204 in a pre-assembled state.

Once the first traction elements 216 are inserted in the lower layer221, the upper layer 222 is layered upon the lower layer 221 in aback-to-back arrangement, such that the substrate 228 a of the lowerlayer 221 is on top and contacts the substrate 228 b of the upper layer222, as shown in FIGS. 5A and 6A. Accordingly, the flanges 244 of thefirst traction elements 216 are interposed between the upper layer 222and the lower layer 221. More specifically, the flanges 244 of the firsttraction elements 216 are disposed between and contact the substrate 228a of the lower layer 221 and the substrate 228 b of the upper layer 222.In some examples, the torsion plies 224 a, 224 b may be stacked in aback-to-face arrangement, whereby the plies 223, 224 of each of thelayers 221, 222 are arranged atop the respective substrates 228 a, 228b, and the substrate 228 b of the upper layer 222 contacts the strand226 of the plies 222, 223 of the lower layer 221, or vice-versa.Alternatively, the layers 221, 222 may be arranged face-to-face, wherebythe plies 223, 224 of each layer 221, 222 face inward towards each othersuch that the plies 222, 223 of the lower layer 221 and the plies 222,223 of the upper layer 222 are in facing contact with each other.

As discussed above, the one or more of the fasteners 252 of theground-engaging assembly 218 may also be configured to engage the plies223, 224 of the upper layer 222 thereby securing each of theground-engaging assembly 218, the lower layer 221, the first tractionelements 216, and the upper layer 222 as a single assembly for placementinto the mold cavity 1006. Additionally, or alternatively, theconnecting members 250 and/or the traction elements 248 of theground-engaging assembly 218 may be entangled with the strands 226 ofone or more of the layers 221, 222 to secure a position of theground-engaging assembly 218 with respect to the one or more of thelayers 221, 222.

As shown in FIG. 13B, the assembled components 216, 218, 221, 222 of theoutsole 204 are inserted between the mold plates 1002, 1004 within themold cavity 1006. At this point, the mold 1000 is closed by moving themold plates 1002, 1004 toward one another or by moving one of the moldplates 1002, 1004 toward the other mold plate 1002, 1004. It should benoted that while the plies 222, 224 are described as beingpre-impregnated with resin material, the plies 222, 224 couldadditionally be supplied with resin 220 that is infused within the mold1000 via an inlet 1010 once the mold plates 1002, 1004 are closed.Additionally or alternatively, the resin 220 may be poured into the moldcavity 1006 prior to closing the mold 1000. The injected or poured resin220 could be in addition to the impregnated resin of the strands 226, oralternatively, could be used in place of the impregnated resin 220.

Once closed, the mold 1000 applies heat and pressure to the stackedlayers 221, 222 disposed within the mold cavity 1006 to activate theresin 220 associated with the strands 226. The heat and pressure appliedto the stacked layers 221, 222 causes the particular shape of the moldcavity 1006 to be imparted to the stacked plies 222, 224 and, oncecured, the resin 220 associated with the stacked layers 221, 222 toharden and retain the desired shape. Additionally, the hardened resin220 at least partially encapsulates the traction elements 248, theconnecting members 250 of the ground-engaging assembly 218 to attach tothe ground-engaging assembly 218 to the outsole 204, as shown in FIGS.5B, 6B, and 13C.

The foregoing processes may be used to form outsole plates that may beused to manufacture custom-made footwear. For instance, variousmeasurements relating to forces applied by an athlete during use of thearticle of footwear may be taken into consideration in determining anoptimal configuration of the ground-engaging assembly. The customizedground-engaging assembly may be provided as a unitary assembly includingthe traction elements 248, the connecting members 250, and the fasteners252 and easily assembled to one or more plies 222, 224 of compositefibers 227 without the need for custom molding hardware.

Custom outsole plates may further allow for tailoring of the stiffnessof the plate for a particular wearer of the footwear. For instance, thetendon stiffness and calf muscle strength of an athlete may be measuredto determine a suitable stiffness of the plate for use by the athlete.Here, the stiffness of the outsole plate can vary with the strength ofthe athlete or for the size/condition of the athlete's tendons.Additionally or alternatively, the stiffness of the plate may betailored based on biomechanics and running mechanics of a particularathlete, such as how the angles of the athlete's joints change duringrunning movements. In some examples, force and motion measurements ofthe athlete are obtained before manufacturing a custom plate for theathlete. In other examples, plates are manufactured in particular rangesor increments of stiffness to provide semi-custom footwear such thatindividual athletes may select a suitable stiffness.

In addition to improved performance characteristics, the describedimplementations of the sole structure 200 provide improvedmanufacturability of customized footwear by facilitating a modularapproach to assembly. For example, any one or more of the components216, 218, 222, 224 may be substituted for an alternative correspondingcomponent providing different dimensional and/or material properties, asdesired.

The following Clauses provide an exemplary configuration for an articleof footwear and a method of forming a plate for an article of footweardescribed above.

Clause 1: A sole structure for an article of footwear, the solestructure comprising: a first ply including a first bundle of fibersaffixed to a first substrate; a second ply including a second bundle offibers affixed to a second substrate; a traction element having a firstportion disposed between the first substrate and the second substrateand a second portion extending from one of the first ply and the secondply; and a resin that consolidates the first bundle of fibers and thesecond bundle of fibers.

Clause 2: The sole structure of Clause 1, wherein the first portion is aflange and the second portion is a ground-engaging projection extendingfrom the flange.

Clause 3: The sole structure of Clause 2, wherein the projectionincludes a constantly decreasing taper in a direction extending awayfrom the flange.

Clause 4: The sole structure of Clauses 2 or 3, wherein the flange is incontact with at least one of the fibers of the first bundle of fibersand with the fibers of the second bundle of fibers.

Clause 5: The sole structure of Clause 1, wherein at least one of thefirst portion and the second portion of the traction element is incontact with at least one of the fibers of the first bundle of fibersand with the fibers of the second bundle of fibers.

Clause 6: The sole structure of any of the preceding clauses, whereinthe at least one of the first substrate and the second substrateincludes an aperture for receiving the second portion of the tractionelement.

Clause 7: The sole structure of Clauses 1-5, wherein the first substrateis in contact with the second substrate.

Clause 8: The sole structure of any of the preceding clauses, whereinthe second portion of the traction element extends through at least oneof the first substrate and the second substrate.

Clause 9: The sole structure of any of the preceding clauses, whereinthe second portion of the traction element extends through the fibers ofat least one of the first bundle of fibers and the second bundle offibers.

Clause 10: The sole structure of any of the preceding clauses, whereinthe second portion of the traction element extends between adjacentsegments of at least one of the first bundle of fibers and the secondbundle of fibers.

Clause 11: The sole structure of Clause 1, wherein the first portion ofthe traction element is an anchor portion and the second portion of thetraction element is a cleat.

Clause 12: The sole structure of Clause 11, wherein the anchor portionis disposed between the first substrate and the second substrate.

Clause 13: The sole structure of Clauses 11 or 12, wherein the anchorportion includes a cleat-retention feature operable to receive andretain a portion of the cleat therein.

Clause 14: The sole structure of Clause 13, wherein the cleat-retentionfeature includes a first series of threads operable to matingly receivea second series of threads of the cleat.

Clause 15: The sole structure of any of the preceding clauses, whereinthe resin is a polymeric resin.

Clause 16: The sole structure of any of the preceding clauses, whereinthe first bundle of fibers and the second bundle of fibers include atleast one of carbon fibers, boron fibers, glass fibers, and polymericfibers.

Clause 17: The sole structure of any of the preceding clauses, whereinthe first bundle of fibers and the second bundle of fibers are affixedto respective ones of the first substrate and the second substrate viastitching.

Clause 18: The sole structure of Clause 17, wherein at least one of thefirst bundle of fibers and the second bundle of fibers includes firstfibers comingled with second fibers, the second fibers including atleast one of a different length, thickness, melting temperature, andtensile strength than the first fibers.

Clause 19: The sole structure of Clause 18, wherein at least one of thestitching, the first substrate, the second substrate, the first fibers,and the second fibers comprise a thermoplastic material.

Clause 20: The sole structure of Clause 1, wherein at least one of thefibers of the first bundle of fibers, the fibers of the second bundle offibers, the first substrate, and the second substrate comprise athermoplastic material.

Clause 21: An article of footwear incorporating the sole structure ofany of the preceding clauses.

Clause 22: The article of footwear of Clause 21, wherein the tractionelement forms a portion of a ground-engaging surface of the article offootwear. The foregoing description has been provided for purposes ofillustration and description. It is not intended to be exhaustive or tolimit the disclosure. Individual elements or features of a particularconfiguration are generally not limited to that particularconfiguration, but, where applicable, are interchangeable and can beused in a selected configuration, even if not specifically shown ordescribed. The same may also be varied in many ways. Such variations arenot to be regarded as a departure from the disclosure, and all suchmodifications are intended to be included within the scope of thedisclosure.

Clause 23: A method of forming a sole structure for an article offootwear, the method comprising attaching a first bundle of fibers to afirst substrate to form a first component; attaching a second bundle offibers to a second substrate to form a second component; positioning afirst portion of a traction element between the first substrate and thesecond substrate; extending a second portion of the traction elementfrom one of the first component and the second component; andconsolidating the first bundle of fibers and the second bundle of fiberswith a resin.

Clause 24: The method of Clause 23, wherein positioning a first portionof a traction element between the first substrate and the secondsubstrate includes positioning a flange of the traction element betweenthe first substrate and the second substrate and extending a secondportion of the traction element from one of the first component and thesecond component includes extending a projection of the traction elementfrom the one of the first component and the second component.

Clause 25: The method of Clause 24, further comprising providing theprojection with a constantly decreasing taper in a direction extendingaway from the flange.

Clause 26: The method of Clauses 24 or 25, further comprising placingthe flange in contact with at least one of the fibers of the firstbundle of fibers and with the fibers of the second bundle of fibers.

Clause 27: The method of Clause 23, further comprising placing at leastone of the first portion and the second portion of the traction elementin contact with at least one of the fibers of the first bundle of fibersand with the fibers of the second bundle of fibers.

Clause 28: The method of any of the preceding Clauses, furthercomprising placing the fibers of the first bundle of fibers in contactwith the second substrate.

Clause 29: The method of Clauses 23-27, further comprising placing thefirst substrate in contact with the second substrate.

Clause 30: The method of any of the preceding Clauses, furthercomprising extending the second portion of the traction element throughat least one of the first substrate and the second substrate.

Clause 31: The method of any of the preceding Clauses, furthercomprising extending the second portion of the traction element throughthe fibers of at least one of the first bundle of fibers and the secondbundle of fibers.

Clause 32: The method of any of the preceding Clauses, furthercomprising extending the second portion of the traction element betweenadjacent segments of at least one of the first bundle of fibers and thesecond bundle of fibers.

Clause 33: The method of Clause 23, wherein positioning a first portionof a traction element between the first substrate and the secondsubstrate includes positioning an anchor portion of the traction elementbetween the first substrate and the second substrate and extending asecond portion of the traction element from one of the first componentand the second component includes extending a cleat from the one of thefirst component and the second component.

Clause 34: The method of Clause 33, further comprising positioning theanchor portion between the first substrate and the second substrate.

Clause 35: The method of Clauses 33 or 34, further comprising providingthe anchor portion with a cleat-retention feature operable to receiveand retain a portion of the cleat therein.

Clause 36: The method of Clause 35, further comprising providing thecleat-retention feature with a first series of threads operable tomatingly receive a second series of threads of the cleat.

Clause 37: The method of any of the preceding Clauses, whereinconsolidating the first bundle of fibers and the second bundle of fiberswith resin includes consolidating the first bundle of fibers and thesecond bundle of fibers with a polymeric resin.

Clause 38: The method of any of the preceding Clauses, wherein attachinga first bundle of fibers to a first substrate and attaching a secondbundle of fibers to a second substrate includes attaching a first bundleof fibers and a second bundle of fibers including at least one of carbonfibers, boron fibers, glass fibers, and polymeric fibers.

Clause 39: The method of any of the preceding Clauses, wherein attachinga first bundle of fibers to a first substrate and attaching a secondbundle of fibers to a second substrate includes attaching a first bundleof fibers and a second bundle of fibers to respective ones of the firstsubstrate and the second substrate via stitching.

Clause 40: The method of Clause 39, wherein attaching a first bundle offibers to a first substrate and attaching a second bundle of fibers to asecond substrate includes attaching a first bundle of fibers and asecond bundle of fibers each having first fibers comingled with secondfibers, the second fibers including at least one of a different length,thickness, melting temperature, and Young's modulus than the firstfibers.

Clause 41: The method of Clause 40, further comprising forming at leastone of the stitching, the first substrate, the second substrate, thefirst fibers, and the second fibers from a thermoplastic material.

Clause 42: The method of Clause 23, further comprising forming at leastone of the fibers of the first bundle of fibers, the fibers of thesecond bundle of fibers, the first substrate, and the second substratefrom a thermoplastic material.

Clause 43: The method of any of the preceding Clauses, furthercomprising incorporating the sole structure of any of the precedingClauses into an article of footwear.

Clause 44: The method of Clause 43, further comprising forming a portionof a ground-contacting surface of the article of footwear with thetraction element.

Clause 45: A sole structure for an article of footwear, the solestructure formed by a process comprising the steps of: attaching a firstbundle of fibers to a first substrate to form a first component;attaching a second bundle of fibers to a second substrate to form asecond component; positioning a first portion of a traction elementbetween the first substrate and the second substrate; extending a secondportion of the traction element from one of the first component and thesecond component; and consolidating the first bundle of fibers and thesecond bundle of fibers with a resin.

Clause 46: The sole structure of Clause 45, wherein the first portion isa flange and the second portion is a ground-engaging projectionextending from the flange.

Clause 47: The sole structure of Clause 46, wherein the projectionincludes a constantly decreasing taper in a direction extending awayfrom the flange.

Clause 48: The sole structure of Clauses 46 or 47, wherein the flange isin contact with at least one of the fibers of the first bundle of fibersand with the fibers of the second bundle of fibers.

Clause 49: The sole structure of Clause 45, wherein at least one of thefirst portion and the second portion of the traction element is incontact with at least one of the fibers of the first bundle of fibersand with the fibers of the second bundle of fibers.

Clause 50: The sole structure of any of the preceding Clauses, whereinthe fibers of the first bundle of fibers are in contact with the secondsubstrate.

Clause 51: The sole structure of Clauses 45-49, wherein the firstsubstrate is in contact with the second substrate.

Clause 52: The sole structure of any of the preceding Clauses, whereinthe second portion of the traction element extends through at least oneof the first substrate and the second substrate.

Clause 53: The sole structure of any of the preceding Clauses, whereinthe second portion of the traction element extends through the fibers ofat least one of the first bundle of fibers and the second bundle offibers.

Clause 54: The sole structure of any of the preceding Clauses, whereinthe second portion of the traction element extends between adjacentsegments of at least one of the first bundle of fibers and the secondbundle of fibers.

Clause 55: The sole structure of Clause 45, wherein the first portion ofthe traction element is an anchor portion and the second portion of thetraction element is a cleat.

Clause 56: The sole structure of Clause 55, wherein the anchor portionis disposed between the first substrate and the second substrate.

Clause 57: The sole structure of Clauses 55 or 56, wherein the anchorportion includes a cleat-retention feature operable to receive andretain a portion of the cleat therein.

Clause 58: The sole structure of Clause 57, wherein the cleat-retentionfeature includes a first series of threads operable to matingly receivea second series of threads of the cleat.

Clause 59: The sole structure of any of the preceding Clauses, whereinthe resin is a polymeric resin.

Clause 60: The sole structure of any of the preceding Clauses, whereinthe first bundle of fibers and the second bundle of fibers include atleast one of carbon fibers, boron fibers, glass fibers, and polymericfibers.

Clause 61: The sole structure of any of the preceding Clauses, whereinthe first bundle of fibers and the second bundle of fibers are stitchedto respective ones of the first substrate and the second substrate viastitching.

Clause 62: The sole structure of Clause 61, wherein at least one of thefirst bundle of fibers and the second bundle of fibers includes firstfibers comingled with second fibers, the second fibers including atleast one of a different length, thickness, melting temperature, andYoung's modulus than the first fibers.

Clause 63: The sole structure of Clause 62, wherein at least one of thestitching, the first substrate, the second substrate, the first fibers,and the second fibers comprise a thermoplastic material.

Clause 64: The sole structure of Clause 45, wherein at least one of thefibers of the first bundle of fibers, the fibers of the second bundle offibers, the first substrate, and the second substrate comprise athermoplastic material.

Clause 65: An article of footwear incorporating the sole structure ofany of the preceding Clauses.

Clause 66: The article of footwear of Clause 65, wherein the tractionelement forms a portion of a ground-contacting surface of the article offootwear.

The foregoing description has been provided for purposes of illustrationand description. It is not intended to be exhaustive or to limit thedisclosure. Individual elements or features of a particularconfiguration are generally not limited to that particularconfiguration, but, where applicable, are interchangeable and can beused in a selected configuration, even if not specifically shown ordescribed. The same may also be varied in many ways. Such variations arenot to be regarded as a departure from the disclosure, and all suchmodifications are intended to be included within the scope of thedisclosure.

What is claimed is:
 1. A sole structure for an article of footwear, thesole structure comprising: a first layer including a first bundle offibers affixed to a first substrate; a second layer including a secondbundle of fibers affixed to a second substrate; a traction elementhaving a first portion disposed between the first substrate and thesecond substrate and a second portion extending from one of the firstlayer and the second layer; and a resin that consolidates the firstbundle of fibers and the second bundle of fibers.
 2. The sole structureof claim 1, wherein the first portion is a flange and the second portionis a ground-engaging projection extending from the flange.
 3. The solestructure of claim 2, wherein the ground-engaging projection includes aconstantly decreasing taper in a direction extending away from theflange.
 4. The sole structure of claim 2, wherein the flange is incontact with at least one of the first substrate and the secondsubstrate.
 5. The sole structure of claim 1, wherein at least one of thefirst portion and the second portion of the traction element is incontact with at least one of the fibers of the first bundle of fibersand with the fibers of the second bundle of fibers.
 6. The solestructure of claim 1, wherein the first substrate is in contact with thesecond substrate.
 7. The sole structure of claim 1, wherein the secondportion of the traction element extends through at least one of thefirst substrate and the second substrate.
 8. The sole structure of claim1, wherein the second portion of the traction element extends throughthe fibers of at least one of the first bundle of fibers and the secondbundle of fibers.
 9. The sole structure of claim 1, wherein the secondportion of the traction element extends between adjacent segments of atleast one of the first bundle of fibers and the second bundle of fibers.10. The sole structure of claim 1, wherein the at least one of the firstsubstrate and the second substrate includes an aperture for receivingthe second portion of the traction element.
 11. The sole structure ofclaim 1, wherein the first bundle of fibers and the second bundle offibers include at least one of carbon fibers, boron fibers, glassfibers, and polymeric fibers.
 12. A method of forming a sole structurefor an article of footwear, the method comprising: attaching a firstbundle of fibers to a first substrate to form a first component;attaching a second bundle of fibers to a second substrate to form asecond component; positioning a first portion of a traction elementbetween the first substrate and the second substrate; extending a secondportion of the traction element from one of the first component and thesecond component; and consolidating the first bundle of fibers and thesecond bundle of fibers with a resin.
 13. The method of claim 12,wherein positioning a first portion of a traction element between thefirst substrate and the second substrate includes positioning a flangeof the traction element between the first substrate and the secondsubstrate and extending a second portion of the traction element fromone of the first component and the second component includes extending aprojection of the traction element from the one of the first componentand the second component.
 14. The method of claim 13, further comprisingproviding the projection with a constantly decreasing taper in adirection extending away from the flange.
 15. The method of claim 13,further comprising placing the flange in contact with at least one ofthe fibers of the first bundle of fibers and with the fibers of thesecond bundle of fibers.
 16. The method of claim 12, further comprisingplacing at least one of the first portion and the second portion of thetraction element in contact with at least one of the fibers of the firstbundle of fibers and with the fibers of the second bundle of fibers. 17.The method of claim 12, further comprising placing the fibers of thefirst bundle of fibers in contact with the second substrate.
 18. Themethod of claim 12, further comprising placing the first substrate incontact with the second substrate.
 19. The method of claim 12, furthercomprising extending the second portion of the traction element throughat least one of the first substrate and the second substrate.
 20. Themethod of claim 12, further comprising extending the second portion ofthe traction element through the fibers of at least one of the firstbundle of fibers and the second bundle of fibers.